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CHAPTER 1
INTRODUCTION
AAC was invented in mid-1923 in Sweden. It is also known as Autoclaved Cellular
Concrete (ACC) or Autoclaved Ligtweigt Concrete (ALC). !roduction "rocess o#
AAC is #airl$ sim"le. It is made wit made wit a mi%ture o# #l$ as& lime& cement&
g$"sum& an aeration agent and water. Aeration "rocess& im"arts it a cellular ligt-weigt
structure. AAC "roducts are "recast in various si'es and "rovide structure& insulation&
and #ire and mold resistance.
AAC "roducts are o##ered in various sa"es and si'es including ut not limited to
locks& wall "anels& #loor and roo# "anels& and lintels. se o# Autoclaved Aerated
Concrete (AAC) locks in construction industr$ in India o##ers interesting "ro"osition
#or various segments in te societ$. *or a "ro+ect develo"er it means #aster and lower
cost construction. *or environmentall$ conscious it means eco-#riendl$ "roducts and #or
tose wo occu"$ uildings uilt wit AAC locks it means etter sa#et$ and lower
energ$ costs #or cooling or eating. !rimar$ raw material #or AAC is #l$ as.
,ousands o# tonnes o# #l$ as is generated $ termal "ower "lants ever$da$
and its dis"osal is a cause o# concern. oreover& using #l$ as does not arm te
environment at all. In #act using #l$ as takes care o# issues related to dis"osal o# #l$ as.
,ere#ore $ using #l$ as to "roduce AAC "roducts "rovides a sustainale& economic
and environment #riendl$ o"tion. At te end it all translates to a etter world #or #uture
generations.
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Types of Aerocon bricks
ne interesting as"ect o# Aerocon rick is tat it lets te user uild te walls o# wit te
tickness o# is coice. Contrar$ to te wall made $ traditional ricks& walls made
wit Aerocon ricks are tinner ut are still sustainale.
/owever& de"ending on di##erent various needs o# internal and e%ternal walls&
Aerocon ricks are availale in di##erent si'es and varied tickness as #ollows. Aerocon
ricks are currentl$ availale in tree si'es0 In#ill& umo& and ,ermal locks
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Infill blocks
,e si'e o# te In#ill Aerocon rick is 4 mm and te tickness varies in te
ranges o# 56&1&126&16&2 mm. ,e main advantage o# In#ill locks is tat te$ caneasil$ re"lace 7 o# te concrete in roo# slas and tus el" in saving signi#icant
amounts o# concrete& steel& laor& water& "laster etc. ,ese locks are es"eciall$ suitale
#or uilding roo#s in large column-#ree constructions.
Jumbo blocks
umo locks are t$"icall$ in te si'e o# 43 mm& and tickness ranges #rom
56&1&126&16& to 2 mm. ,e uni8ue large si'e o# umo Aerocon ricks results in
te usage o# muc #ewer ricks and ence less mortar is re8uired. ,ese ricks are more
suitale #or non-load earing walls& multi-storeid uildings etc.
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Therml blocks
,ese locks are also called as Aerocool termal locks wose si'e and tickness is342 mm and 6 mm res"ectivel$. ,ese locks are ideal #or roo#ing since te$
dela$ te transmission o# eat #low and also el" interiors remain warm during winters
and cool during summers.
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CHAPTER !
CO"PARI#ION $ET%EEN AEROCON $RIC AND
C'A( $RIC
Comprison be)*een Prme)er AAC $locks Cly $ricks
Au)ocl+e, Aer)e,
Concre)e -AAC.
blocks n, cly
bricks #eril
1 Soil Consum"tion ses #l$ as wic is a ne s8 #t o# car"ettermal "ower "lant area wit cla$ rick
waste "roduct tus walling will consume
no consum"tion o# to" 26.6 kg o# to" soil
soil
2 *uel Consum"tion ne s8 #t o# car"et ne s8 #t o# car"et
area wit AAC locks area wit cla$ rickswill consume 1 kg o# will consume : kg o#
coal coal
3 C2 ;mission ne s8 #t o# car"et ne s8 #t o# car"etarea will emit 2.2 kg o# area will emit 15. kg
C2 o# C2
< Laour rgani'ed sector wit norgani'ed sector
"ro"er /= "ractices wit ram"ant use o#
cild laour
6 !roduction *acilit$ State-o#-te-art #actor$ nealt$ working
#acilit$ conditions due to
to%ic gases
,a% Contriution Contriutes to >oes not contriute
government ta%es in to government
#orm o# Central e%ce8uer ;%cise& ?A, and
ctroi
5 Si'e 26 mm % 2
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weigt leading to
savings in steel and
concrete
13 ;nerg$ Saving A""ro%.37 eating Bone
and cooling
The ,+n)/es of Aerocon blocks o+er con+en)ionl clybricks
1 Aerocon Dlocks are an innovative "roduct in te green uilding revolution.
2 Aerocon locks are te new locks in walling materials&sustituting conventional and environmentall$ unsustainale materialslike cla$ ricks& concrete and ollow locks.
3 ,e raw materials used in te manu#acture o# tese locks areenvironmentall$ #riendl$ and are certi#ied green "roducts. ,e asic rawmaterials used in "roduction o# Aerocon locks are Cement& *l$ as& lime andwater.
4
Aerocon locks can e "lastered& "ainted& and dr$ lined or tiled.
5 Aerocon lock is e%tremel$ ligt& +ust one-tird te weigt o# cla$ ricksor one-#ourt te densit$ o# =.C.C. ,e$ are muc easier to andle on te site.
6 ,e$ are eas$ to install and can com"lete te construction "rocedure in asorter s"an in case o# scarcit$ o# laour and in te usage o# mortars. ,ere8uired time to com"lete a uilding wit aerocon locks is 13 lesser tan tato# te conventional uilding materials.
7 ,e edges o# te locks are suc tat te$ allow eas$ workailit$ andaccurate dimensioning and are eas$ to cut& drill& nail& sa"e and case usingordinar$ wood working tools. !ower tools can e used #or ra"id casing #oremedding service lines.
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1 Aerocon locks can e cut virtuall$ in an$ sa"e or angle making teme%tremel$ ada"tale.
2Aerocon lock covers te same area as tat 1< cla$ ricks do enaling a#aster construction results in saving o# laour& time and material.
3 Aerated concrete is "er#ect uilding material #or an$ climate. It is used touild all kinds o# walls0 e%terior and interior earing and non-earing wallsoundation walls& "artition walls as #illing agent in #ramework structures& wall"artitions& #ire division walls& etc.
4 Aerocon e%cellent termal "ro"erties el"s in saving recurring energ$ costs
o# eating and cooling. ,e termal resistance comined wit te ene#its o#termal mass inertia and wole wall coverage eliminates te need #oradditional insulation.
5 Aerocon locks are availale in various si'es and sa"es.,e$ are availale in
tree t$"esE In#ill locks& umo locks and ,ermal locks. ,e$ are includedinto te categor$ o# Freen Duilding materials ecause te$ don t emit ?C
(?olatile rganic Com"ounds) wic cause environmental "ollution.
6 A"art #rom eing eco-#riendl$ tese locks are also ligt weigt wit igtermal insulation& #ire resistance& sound insulation& ave strengt and durailit$&ave consistent 8ualit$ control and gives a "er#ect #inis wit dimensional
stailit$. Duildings constructed out o# tese locks ensure long term
sustainailit$ and save a lot o# water during te construction.
7 ;%cluding te eco-#riendl$ caracteristics o# tese locks& te$ are also used
in construction #or various oter reasons. ,ere are a numer o# "rolems
involved in ac8uiring te sand and ricks and also te "rices o# tese asic
materials are iking u". As te traditional construction materials ave a iger
"rice te initiation o# Aerocon locks acts as etter sustitutes wit a##ordale
"rices. >ue to tese reasons te Aerocon locks are in great demand.
8 /ence& it is one o# te revolutionar$ materials tat can e used to make teworld a etter& greener and cleaner "lace to live in. It is a revolutionar$ materialtat
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comines te uni8ue "ro"erties suc as durailit$ and strengt& low weigt& ver$sim"le construction tecnolog$ and e%cellent environmental "er#ormance.
CHAPTER 0
DE#IN CON#IDERATION#
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enerl consi,er)ions
AAC masonr$ com"onents(lock units) can e used to uild load earing or non loadearing walls.
1 -lock units used to uild "ilasters.
2
-lock units used to uild ond eams and lintels.3 Control +oints on AAC rein#orced walls must e "laced at ma%imum 1 #t.
o.c.
Ins)ll)ion ui,e1 Ceck #oundation.2 =eceiving and distriution o# AAC wall units.
Ins)ll)ion re2uiremen)s1 ,ools2 ;8ui"ment3 ter materials4 Installing -lock #or "ilasters in #irst course
'yin/ )he firs) course -le+ellin/ course.1 La$ te #irst course over a semi-dr$ cement mortar levelling ed- GH to 2H
tick.
2 Corner locks are laid #irst and te #irst course sould e com"leted
e#ore second course installation.3 nce corner locks are "laced a""l$ tin ed mortar& to te vertical +oints
#or oter locks.4 ,in ed mortar 11H inc to 1:H
Cu))in/ blocks -,3us)men)s n, chses.1 A and saw or and saw to cut te locks to s"eci#ic lengts.
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Plcin/ con)rol 3oin)s in firs) course
1 ,ese are vertical +oints taken troug te #ull wall tickness& and #romottom to to".
2 3:H to GH tick.3 a%imum s"acing etween control +oints sould e 16 #t.
'yin/ )he subse2uen) courses
1 *or suse8uent courses use onl$ tin ed mortaring on all +oints etweenAAC locks.
2 inimum overla""ing o# vertical +oints etween la$ers sould e
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U)ili)ies ins)ll)ion f)er )he *lls re buil)
1 *or electrical conduits and "i"ing installation& a case is cut using anelectrical router or a casing tool.
2 Jen re8uired de"t o# case is igger tan ma%imum de"t recommended&additional -locks are used to lodge te "i"es or interru"t wall continuit$.
3
A#ter installation& te case are #illed wit re"air mortar or cement sand mortar.
Ren,ers1 Sur#ace "atcing0
=as" lock +oints and oter areas were AAC sur#ace is out o# "lane.
1 Sur#ace must e cleaned using a scru rus and an$ loose or damagedmaterial e removed.
2 A ruer #loat is commonl$ used to smoot te wall sur#ace.
3 *ier glass mes0
,is sould e installed directl$ over one la$er o# render in all control
+oints& around windows& doors and utilit$ locations.
6inishes
1 AAC masonr$ walls can e #inised wit stucco & acr$lic te%ture coats& or acomination o# ot& also laminated stones& ceramic or cla$ tiles& concrete"ieces and ornamental "roducts5
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R* ")eril
6ly Ash or #n,
Ke$ ingredient #or manu#acturing AAC locks is silica ric material like #l$ as or sand.
ost o# te AAC com"anies in India use #l$ as to manu#acture AAC locks. *l$ as is
mi%ed wit water to #orm #l$ as slurr$. Slurr$ tus #ormed is mi%ed wit oter
ingredients like lime "owder& cement& g$"sum and Aluminum "owder in 8uantities
consistent wit te reci"e. Alternatel$ sand can also e used to manu#acture AAClocks. A wet all mill #inel$ grinds sand wit water converting it into sand slurr$.
Sand slurr$ is mi%ed wit oter ingredients +ust like #l$ as slurr$.
'ime Po*,er
Lime "owder re8uired #or AAC "roduction is otained eiter $ crusing limestone to
#ine "owder at AAC #actor$ or $ directl$ "urcasing it in "owder #orm. Altoug
"urcasing lime "owder migt e little costl$& man$ manu#acturers o"t #or it rater tan
investing in lime crusing e8ui"ment like all mill& +aw cruser& ucket elevators& etc.
Lime "owder is stored in silos #aricated #rom mild steel (S) or uilt using rick and
mortar de"ending o# individual "re#erences.
Cemen)
63-grade rdinar$ !ortland Cement (!C) #rom re"uted manu#acturer is re8uired #or
manu#acturing AAC locks. Cement su""lied $ mini "lants is not recommended due to
drastic variations in 8ualit$ over di##erent atces. Some AAC #actories migt "lan teir
ca"tive cement "rocessing units as suc an unit can "roduce cement as well as
"rocess lime. Suc #actories can o"t #or ma+or "lant clinker and manu#acture teir own
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cement #or AAC "roduction. Cement is usuall$ stored in silos.
ypsum
F$"sum is easil$ availale in te market and is used in "owder #orm. It is stored in silos.
Aluminum Po*,er7Ps)e
Aluminum "owder"aste is easil$ availale #rom various manu#acturers. As ver$ small
8uantit$ o# Aluminum "owder"aste is re8uired to e added to te mi%ture& it is usuall$
weiged manuall$ and added to te mi%ing unit.
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CHAPTER 8
PRODUCTION PROCE##
R* ")eril Prepr)ion n, #)or/e
,e #irst ste" o# AAC "roduction is grinding o# silica ric material (sand& #l$ as& etc) in
all mills. *or di##erent materials& di##erent "rocessing is ado"ted& suc as dr$ grinding
(into "owder)& wet grinding (into slurr$) or mi%ed grinding wit 8uicklime (Ca).
,ere are two metods #or mi%ed milling.
ne is dr$ mi%ing to "roduce inding material& and te oter metod is wet
mi%ing. Since most 8uicklime is agglomerate& it sould e crused and ten grinded.
F$"sum is normall$ not all milled se"aratel$. It is grinded wit #l$ as or wit
8uicklime& or it could e grinded wit te same miller #or 8uicklime in turn. ter
su""lementar$ and cemicals are also ave to e "re"ared. =aw material storage assures
te continuous "roduction and material stailit$.
,e continuous "roduction guarantees te non-sto" on-time su""l$& and te
material stailit$ guarantees te 8ualit$ o# "roducts& since te raw material migt come
#rom di##erent sources& wit di##erent 8ualities. =aw material "re"aration storage is
te "re-ste" #or "ro"ortioning atcing. ,is "re-ste" guarantees te raw material meette standard #or AAC "roduction& and it is also #inises te storage& omogeni'ation and
aging "rocess. It is te asic "rocess tat assures te smoot "roduction and "roduction
8ualit$.
Dosin/ n, mi9in/
aintaining ratio o# all ingredients as "er te selected reci"e is critical to ensure
consistent 8ualit$ o# "roduction. ,is is accom"lised $ using various control s$stems
to measure and release te re8uired 8uantit$ o# various raw materials. A dosing and
mi%ing unit is used to #orm te correct mi% to "roduce Autoclaved Aerated Concrete
(AAC) locks. *l$ assand slurr$ is "um"ed into a se"arate container.
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nce te desired weigt is "oured in& "um"ing is sto""ed. Similarl$ lime "owder&
cement and g$"sum are "oured into individual containers using screw conve$ers. nce
re8uired amount o# eac ingredient is #illed into teir individual containers control
s$stem releases all ingredients into mi%ing drum.
i%ing drum is like a giant owl wit a stirrer rotating inside to ensure "ro"er mi%ing
o# ingredients. Steam migt also e #ed to te unit to maintain tem"erature in range o#
osing unit releases tis mi%ture as "er
set 8uantities into molds #or #oaming.
>osing and mi%ing "rocess is carried out continuousl$ ecause i# tere is along ga" etween carging and discarging o# ingredients& residual mi%ture migt start
ardening and coke u" te entire unit. In modern "lants& entire dosing and mi%ing
o"eration is com"letel$ automated and re8uires minimum uman intervention.
,is entire o"eration is monitored using control s$stems integrated wit
com"uter and CC,? cameras. As wit an$ industrial o"eration& tere is "rovision #or
uman intervention and emergenc$ actions integrated inside te control s$stem.
Cs)in/: 6omin/ n, Pre4curin/
nce te desired mi% is read$& it is "oured into moulds. ,ese moulds can e o# various
si'es de"ending on te "roduction ca"acit$ o# a manu#acturing unit. nce mi% is
"oured into moulds& it is read$ #or "re-curing. A#ter casting& te slurr$ in molds will e
in te "re-curing camer to #inis #oaming and ardening. *oaming and ardening
actuall$ starts wen te slurr$ is #ed into molds& wic includes gas-#orming e%"ansion
and "er#orm& curing to acieve certain strengt& wic is enoug #or cutting. !re-curing
is alwa$s done under set tem"erature.
/ence it is also called as M/eating-room-"re-curing.H !re-curing as not a
com"licated "rocess& ut sould avoid viration. "erations must kee" e$es to monitor$ te
slur$ cange during #oaming and "rovide #eedack to dosing& mi%ing and casting "rocess.
!re-#orm de#ects (cracking& sinking& etc.&) mainl$ occur during te "rocess.
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Cu))in/
>uring tis "rocess& te "re-cured lock goes troug cutting and sa"ing& into di##erent
si'e sa"es as "er re8uirements. ,e ig workailit$ and large variet$ o# si'es make
AAC "roduction more suitale #or massive "roduction wit iger mecani'ation.
Cutting can e done mecanicall$ or manuall$. Jit a cutting macine& te "roduction
e##icienc$ and dimensional accurac$ is easil$ acieved.
Au)ocl+e, Curin/
A#ter cutting into te desired si'es sa"es& green AAC locks are trans#erred into
autoclaves. Autoclaves are used #or steam curing under "ressure. AAC must e "re-curedand steam cured to #inis te "$sical and cemical canges& and ten to acieve enoug
strengt #or desired usage. A atc o# AAC locks is steam cured #or 1-12 ours at a
"ressure o# 12 ar and tem"erature o# 19NC. In ot and umid conditions& AAC locks
undergo last stages o# $dro-termal s$ntesis reaction to trans#orm into a new "roduct
wit re8uired strengt and various "$sical "er#ormances. Autoclaved curing im"arts
inerent "ro"erties and "er#ormance o# AAC.
roupin/
Frou"ing could e te last ste" o# AAC "roduction (in some AAC "lant& te AAC will e
#urter "rocessed into "anels a#ter leaving autoclaves). A#ter te cured AAC leaves te
autoclaves& ins"ection and "ackaging is done.
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16
Process 6lo* Chr)5
6ly Ash ypsum 'ime OPC
Jater
*l$as Jeigt Jeigt Datced
Slurr$ Datced
Datced
!ouring
i%ture
to mi% ingredients
Dricks Casting on ould
>e-molding and Jire Cutting
/i!re
ssu
reSteam
Cur
ing#or
:
/ours
;c
o-
Dric
ks
=ead
$
#o
rSa
le
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"in
R* m)eril
Ouantit$
Aluminum
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CHAPTER ;
ANA'(#I#
"rke)
Selter is tird skin& according to a Ferman Conce"t& wic im"lies its im"ortance ne%t
to uman Skin and Cloting. ,is also sows te attacment o# uman race to tis
#undamental re8uirement.
Duilding aterial accounts #or ma+or com"onent o# te construction cost. >e"ending
on te location te$ can contriute to - 5 7 o# te cost o# construction. Jit te
ever increasing "o"ulation& te demand #or ousing increases. ,is directl$ creates
demand #or tis "rime commodit$ o# uilding.
Add to te aove #act te near$ area o# tis "ro+ect site is undergoing a ma+or
in#rastructure revolution. As =esidential& Commercial& I, com"anies& and Industrial
estalisments are coming in& we can conclude tat te Dlocks unit will "ros"er and
#louris in tis environment.
,ere is a central government gadget noti#ication mandating government
de"artments and C!J> to use 17 *l$ As ased Dricks in teir all constructions-
directl$ o# troug contractors. ,is #actor will el" te marketailit$ o# tis "roduct
immensel$.
*l$ As "olic$ o# te Fovernment also mandates tat 27 o# *l$ as Fenerated $ a
"ower "lant must e given #ree o# cost to S; sector on a "riorit$ asis.
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Crbon Cre,i)s Es)im)es
AAC locks are eing seriousl$ considered #or C> "ro+ects in India #or earning
Caron Credits. As te C;= Fenerated is also relativel$ less& #our or #ive suc unitscan e undled togeter to make a Frou" C> in te same sactors.
,is "ro+ect is likel$ to generate 1 C;= "er eac 5 or : Cuic eter o# Dlocks
"roduction& de"ending on& and su+ect to te C> metodolog$ ado"ted& and te
inter"retation o# additionalit$ and aseline "arameters $ te validating autorit$.
ust #or a roug estimate o# C;=S& #or an annual "roduction o# average si'e AAC
"lant& tat is 1CAnnum& we are likel$ to get around 126 C;=s on #ull
ca"acit$ !roduction. At "resent market rate o# 11.6 ;uros "er C;= and P =s. "er
;uro& we can e%"ect to get additional revenue on C;=. Dut we must e%"ect to take a
cut o# around 2 to 37 o# C;=s& i# we want to #orward sell te C;=s and get te
C> "art s"onsored $ te u$er
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R* ")eril #ui)bili)y
Almost 967 o# te raw materials can e made suitale #or AAC line troug "ro"er mi%
design. Also we can ave man$ di##erent mi% designs #or te same denicit$Qsame
strengt o# Dlocks. Je will el" $ou to get te Dest 8ualit$ locks at o"timal cost $
means o# designing "ro"er i% as "er $our in"ut raw materials.
,e #ollowing are asic guidelines (certainl$ not te #inal call) on te suitailit$ o#
asic raw materials #or AAC.
156ly sh -?.
In,e9 I)em r,e -?.
r4I r4II
(.egree o# amount) R 3
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!5 'ime -@4!;?.
I)em r,e
#uper r5 1s)r5 !
n,r
A(Ca@g)Oualit$ *raction 7 9 56 6
g Oualit$ *raction 7 R 2 6 :
Si2 Oualit$ *raction 7 R 2 6 :
>igestion
s"eed 6-16&min R
>igestion tem"erature & -9
ndigested residue 8ualit$ #raction &7 R 6 13 16
*ineness (.: s8uare ole sieve le#t amount)7 R 1 16 2
C2 Oualit$ *raction 7 R 2 6 5
05 Cemen) -
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85 ypsum7Pls)er -04;?.
CaS< 57
g 27
Cloride .67
!re#eral$ ground residue 9Tm 1-167
;5 Aluminum Po*er -bou) >5>@?.
,$"e and recommendation #or su""l$ de"end on raw materials and mi% #ormula
etal Content A""ro%. UV67 !owder
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CHAPTER ue to ig #ire resistance o##ered $ AAC& structures made #rom AAC ave iger rate
o# survivailit$ in case o# #ire.
#oun, Insul)ion
Sound asor"tion "ro"erties o# AAC make it ideal material #or reducing amient noi
se.AAC is well-suited #or estalisments like os"itals and o##ices situated in nois$
areas.
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Con)ribu)ion )o N)ion
AAC #actories create man$ +os directl$ and indirectl$ creating a social im"act.
Along wit tat te$ "a
%e)her Resis)nceAAC does not deca$& rust& deteriorate or urn. AAC as een #ound to e eart8uake
resistant. AAC structures are known to maintain structural integrit$ in eav$ rains&
e%tremel$ low tem"erature and salt$ air.
Pes) Resis)nce
!rimar$ raw material used to manu#acture AAC is #l$ as. *l$ as (or "ond as) is an
inert material and does not allow termites or oter "ests to survive.
;%cise >ut$ and ?A, contriuting to national econom$
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Pro,uc) Dis,+n)/es
,e ma+or disadvantages o# autoclaved aerated concrete are listed elow.
1 ,e "roduction cost "er unit #or ACC is iger tan oter ordinar$concrete.
2 Bumer o# manu#acturer is limited. So& cost will drasticall$ increase in"laces #ar #rom te manu#acturer and need to travel a long distance.
3 It is not as strong as conventional concrete.
4 ?er$ #ew contractors wo are #amiliar wit ACC.
5 Construction wit autoclaved aerated concrete ma$ will need s"ecial
"ermission.
6 ;nvironmentall$ #riendl$
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CHAPTER @
CONC'U#ION
As a construction s$stem& AAC "rovide signi#icant environment and oterene#its #or te uilding owner. ,e sort and long term e##ect o# using AACcom"ared to man$ oter materials results in lower energ$ consum"tion&reduced o"erating costs& greater sa#et$ and com#ort& and a ealtier and moretroule #ree uilding. ,ese #eatures "rovide a etter investment #or uildingowner and #or environment.
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RE6ERNCE#
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